Condensation products of phenol, formaldehyde, and unsubstituted mononuclear dihydric phenols



Patented Oct. 14, 1952 UNITED PATENT fori-ics coDNsTIoN PRODUCTS -oF l?iilL, FORMALDEHYDE, ANDUNSUBSTITUTED MONONUCLEAR DIHYDRIC PHNOLS Nol'rwi'ng. Applicatib'rilliiiie 11%,"1949, Serial No. 99,582V

s lnctly superior s hide soflpticisjf "flrsrirlslinq tuviesensofteningwith fin aq solutionofYol'll'iailclehyde a delnamorit v1.65 poisss fst a solids' content between `50 and ss determined by the staridarClA. spilt method-for'slidsdetsrflirition. This A. syl?. solids "i'tvelrfninton s con'dul'itec'l by fplecn'g. a gririffami "aiislf sammeln a 2 1/2 irish cup-'sind heating to 'a temperature o f 135; o. fior Lthree hours. The lesidle :is 'weighedand the solids sas-and Water Witlijsb utjl to 15%5nreth nel added top'l'event 'lao'lymerizaton Ihas; ,been lf; nfl fery. Satisfaltryor thislpulrpbsei ,Alternative y, there meyla ilsed paraforlnldehyde dissolved 'in water or in 'a watewsl'eohol mixture to 'bti 3 concentration of 40 to 60% formaldehyde by Weight, or again, paraformaldehyde may be added to 37% formaldehyde to obtain the desired concentration. Such aqueous solutions of formaldehyde .may also contain methanol in an amount of about 1 to 15%.

Instead of adding all of the resorcinol or other dihydric phenol after the preliminary condensation of the monohydric phenol and formaldehyde, a small proportion of the dihydric phenolnot more than 10 parts for each 100 parts of phenol used in the formula-may be added to the original mixture of phenol and formaldehyde before they are condensed. When more than about 10 parts of a dihydric phenol such as resorcinol is added to the initial ingredients in the presence of only suflicient alkali to act as a catalyst, the mixture will gel shortly after heat is applied to it. Accordingly, since only a very small proportion of the resorcinol can be added successfully at the beginning Vof the reaction, it is usually more advantageous in commercial operations to add all of the resorcinol after the preliminary condensation of the phenol and formaldehyde has been effected.

rThe proportions of monohydric phenol and formaldehyde that are reacted together before addition of the main portion of the dihydric phenol are preferably adjusted to produce a reaction product that contains not more than about 2% of free formaldehyde and pri ferably less than 0.75% free formaldehyde at the time that dihydric phenol is added. It is not essential that this initial condensation product contain any free formaldehyde but if the proportion of formaldehyde in the initial composition is too low, anv excessive amount of formaldehydey paraformaldehyde or hexamethylenetetramine will have to be added to effect curing et the finished product. The proportion of formaldehyde that can be used with the monohydric phenol will vary depending upon the amount of resorcinol that is to be added subsequently. When the proportion of resorcinol used is very high, as much as 2.5 mols of formaldehyde may be used for each mol of monohydric phenol. It is preferable, however, to use a smaller proportion of formaldehyde, although if less than 1.3 mols of formaldehyde is used foreach mol of phenol, the amount of curing agent that has to be added to the final product tends to become excessive.

For practical purposes, I prefer to use from about 1.5 to about 2 mols of formaldehyde for each mol of monohydric phenol. Within this range, the amount of dihydric phenol added can all be utilized to advantage, and the quantity of curing agent added to the Jfinished product does not haveto be excessive. Also, the nal product is stable, has a long storage life and a long working life after addition of the curing agent and spreading of the glue.

The degree to which the original phenol and formaldehyde are condensed before addition of the resorcinol may be varied somewhat but these initial reactants are preferably condensed long enough to form phenol-alcohols and polymerize these condensation products to some extent. One convenient way of determining the proper amount of condensation to be applied to the initial mixture of phenol and formaldehyde is to determine either the free formaldehyde content of the mixture, or its water tolerance, or both. These original materials should be sufliciently reacted to lower the free formaldehyde content belowabout 2%, and the reaction product should 4 also be condensed until it will tolerate the addition of from about 0.1 to 5 volumes of water Without causing the resin solution to become cloudy at 70 F.

In the preparation of these products, the cresols and xylenols cannot be substituted entirely for the phenol used in making up the initial reaction product, although a small proportion of one of these monohydric phenols may be substituted for say about 10% of the phenol originally employed.

If any appreciable amount of free formaldehyde is present in the preliminary phenol-formaldehyde condensation product, this material should be cooled before the resorcinol is added to avoid the possibility of gelling the entire product upon the addition of the resorcinol.

Various alkaline catalysts may be employed in preparing the initial condensation product of phenol and formaldehyde, although the alkali used should be of non-Volatile character such caustic soda, caustic potash, sodium carbonate, trisodium phosphate, etc. The use of a volatile alkali such as ammonium hydroxide is apt to cause separation of the resin from solution in the preparation of the initial phenol-formaldehyde reaction product. The amount of the alkaline catalyst should be sufficient to produce a pH of at least 7.5 and preferably a pH of around 8.0 to 8.5 or slightly higher. If too much alkali is added, the excesshas a tendency to keep the initial reaction products of the phenol-formaldehyde in solution. If theWatcr tolerance test is used to determine the end point of the preliminary reaction, this makes it difcult to determine when these initial reactants have been condensed sufficiently for the addition of the resn orcinol. For this reason, it is desirable to adjust the pH of the initial phenol and formaldehyde mixture within the range of about 7.5 to 8.3, although this range is not critical if the reaction end point is determined by the free formaldehyde test. f

There is little advantage in employing more than about 150 parts by Weight of resorcinol for leach 100 parts of phenol in the product. Preferably, not more than 100 parts by weight of resorcinol for each 100 parts of phenol in the product is used. However, if the nal product is to beA cured at elevated temperatures of the order of 300 F., it is desirable to use at least 1C- parts of resorcinol for each 100 parts of phenol. and if the product is to be cured at low temperatures, for example, cold press temperatures of the order of 70 F., it is necessary to employ at least about 75 parts of resorcinol for each 100 parts of phenol in order to obtain a satisfactory flnalproduct. v

,When the dihydric phenol such as resolcinol is added to the initial condensation product of phenol and formaldehyde, it is desirable to add additional alkali, particularly if the nal product is to be .cured by the addition of formaldehyde, paraformaldehyde or hexamethylenetetramine.

The adjustment of the pH at this stage in the process is simply to allow for a drop in pH during the further condensation of the product and if the final product is to have a pH of 6.0 to 7, the addition of alkali along with the dihydric phenol is unnecessary.' On the other hand, if the final productis desired with a pH above 7, additional alkali should be added along With the resorcinol. Any of thev alkalis mentioned above may be used for this purpose and also alkalis such as ammonia may be employed. Volatile alakalis such fas ammonium hydroxide, however, produce .a

stronger reactionand i-tfis .desirable Vwhen they are .used to complete .the condensation at somewhat lower temperatures in order to control the properties of the final product. A

` For thepreparation of afglue to be cured by anaddition offormaldehyde or a formaldehydeliberating agent,lit'is desirable to have .the pH of the phenol-formaldehyde condensation 4product mixed with resorcinol adiusted to the range of about 7 to 9 or 8 to 9 before the condensation of theproduct is completed.

The degree of condensation of the material after addition of resorcinol or other dihydric phenol is determined to a large extentby theultimate'use of the product. If thenal product is to have a very high solids content, the condensation .after addition of .resorcinol may be stopped after the product hasra viscosity of 0.5 poise at a solids .content of 40 to 60%. Such a product would be very watery andin orderto kreduce this product toa material of suitable .viscosity, large proportions `of water would have to be distilled oi under vacuum.

If the i'lnal product is to be used as a glue, it is of course desirable to `carry the second condensation of the material further so that the final glue after distillation of water Ywill have a solids content in the neighborhood of 50 to 70% solids.

If the iinal condensation of the product is carried too far, however, its .storage life is reduced, and for this reason it is preferred not to carry this nal .condensation beyond the point of having a viscosity of 1.65 poises at a solids content of 40 to 60%.

After the final condensation of the product is completed, the amount of water vthat will have to be distilled 01T will depend of course upon the degree of the iinal condensation and the viscosity desired in the final p-roduct. W'hen the material is to be used as a glue in a roller coater operation in' the manufacture of plywood, Yit is usually desirable to obtain a final product with a viscosity of 1Z0-135 at 70 F. on the Stormer viscometer, using a 500 gram weight, although obviously the nal product, particularly for other types of glue, may have a viscosity outside of these limits, such as to 200 at 70 on the Stormer viscometer, using a'500 gram weight.

A particular advantage of the products -of my invention is that they may be used as casting resins as Well as for glues. When the product is to be cast, it may be prepared by the addition of a suitable acid catalyst,.stirred fora few minutes and poured into molds to cure at atmospheric pressure and at a low temperature as will ce explained below in more detail.

The following examples are illustrative of the methods used in practicingmy invention:

.Example I Eighty pounds of phenol, 120 pounds of 37% formaldehyde and 1200 cc. caustic soda solution are charged into a steam-jacketed kettle equipped with a stirring device, a reilux condenser, a vacuum pump and a receiver. The batch is heated to reux and 'allowed to remain at that temperature until one volume of resin solution when cooled to 70 F. will tolerate 2- 31/2 volumes of water, previously cooled to the same temperature. Approximately 30 minutesI are required to complete this reaction at 100 C.

6 sodasolution lare-added' Vtothelbatch. 'lt'h'ej charge is reheated to 4.8O-" and '.held 'within "this range until the viscosity of the resin's'luti'on is "fD' on 1a Gardner 'bubble-'tube vis'cometer. This viscosity is equivalent to 1.0 poise. 'Vacuum vis then applied, and distillationv continued until a, sample shows `.'visco'sity 'of 1Z0-140 at"70 F. one. Stormer'viscomterusing a 500 gram weight.

The iinished resin'solution will have Ya solids contents 65-67%, a .pH-of 8.0-8.3, and a specific -gravity of approximately 1.20.

rmmpzen Eighty pounds ofjphenol, .138 pounds Vof 37% formaldehyde and 1212-00. `30% vcaustic soda A.solu'tionare charged vinto a steam-'jacketed kettle equipped with a stirring device, a reflux-condenser, a, vacuum pump and a receiver. The batch is then heated to reux and allowed to .remain `at that temperature until 'one volume of .resin solution, 'when cooled yto 70 F. will tolerateL2-3l/z volumes of water, previously cooled I 'to the -same temperature. Approximately 30 .minutes are required t'ofcompletethisreactionat The batch is 4then cooled to 50 C. and 88 lbs.

'of resorcinol and 4000 cc.-of `30% caustic `soda solution yare added to the batch. The charge'is reheated to 80-90 C., and held Within-thislrange until'a viscosity of .FIon a Gardner bubble-tube viscom'eter was obtained. This viscosity is equivalent to 1.4 poises. Vacuum is then applied and distillation-continued until a sample shows 'a viscosity of -120-140 at 70 F.

bility of this solution 'is approximately the same 'as those having a pHof 7.6-8.3.

Example III A batch of resin is prepared using the .same

.proportions and procedure as used -in Example I vexceptrthat no caustic ysolution is added to the hatch lat the Vtime the' resorcinol is charged into the kettle.

.The nished vresin will have a viscosity of l20-140 at 70 ia pH of 6.6-"!;0 and a solids content ofl 65-67 k Two pounds of the above resin is weighed in a mixing kettle and to it is added sufficient hypophosphorous acid v(50%) `to lower the pH of the solution to -a pH of 2.0 (approximately .22 cc.

of catalyst). The mix is agitated-at slowspeed for approximately 15 :minutesat room tempera ture, andthen allowed to vstand for 30 vminutes to-allow the'escape of trapped air. The solution is .poured .into ari-open mold, and'cured at atmos pheric pressure at a temperature of 140 F.

After cu-ring fior approximately threefhours -a-tthis temperature, the rcasting can lbe removed from the mold.

Resin solutions prepared by my inventionhav.- ing ua pH as low as 6.0 or as high as 8.5 still `have excellent stability upon storage at room tempera ture over a period of months. These products do not .separate from solution on aging and ycan be diluted with large volumes oi water without precipitating the resin solids.

Such products, 'when'prepared with the vproper viscosity, makeexcellent Wood glues permitting assembly times 4of 11/2 hours at '70 F. and 45 minutes at 90 F., i. e. after the hardening agent is added and the glue is spread. Formaldehyde or paraformaldehyde can be added as a harden-- ing agent if the glue is to be cured at low ternperatures while if higher temperatures are used for pressing, hexamethylenetetramine may also be used, as will be understood by those skilled in the art.

With low density woods such as spruce, poplar, basswood and Douglas fir, these glues can be cured at temperatures as low as 75 while with harder woods such as birch and maple, curing temperatures of at least 100 F. are preferred, although satisfactory products can be obtained even with such hard Woods by curing at a ternperature of 75 F.

rlhe glues oi my invention, particularly when catalyzed with hexamethylenetetramine, have the following desirable properties of a glue adaptable to molding methods in which intricate assemblies are made up and cured inside a ilexi ble bag in a pressure tank; (a) ability to bond at low pressures, (b) ability to bond at low emperatures of the order of 200 F., '(c) long assembly period without premature curing, (d) a high degree of slipperiness atA curing temperatures and (e) ability to render the glues flexible and easy to form.

If desired, of course, these glues may also be used for hot pressing at temperatures well above 200 F.

By condensing the resin composition in accordance with this invention, several unusual properties can be secured in the glue. In particular, when the resin cures, it appears to go through two distinct gel periods. While the materials entering into the resin formulations should yield a homogeneous product, there is reason to believe that certain of the components may exist as separate species in the resin mol ecule. This co-existence of two species in one phase allow one of the components to gel sooner than the second one. This gel which forms initially then dissolves in the substrate whereupon a further condensation occurs yielding a second gel.

The possibility of securing two separate gel phases in an adhesive allows the preparation of an unusual type of material for gluing operations. Whatever the explanation, the combination of resorcinol and phenol found in the resin as prepared following the practice of the invention leads to resins possessing superior charf acteristics.

The resin solutions of this invention are also well suited for making castings, such as the industrial castings used in the manufacture of metal forming dies. My products are distinctive from the ordinary phenolic casting resins in that they contain relatively high proportions of water (80 to 40%) are prepared with a relatively low mole ratio of formaldehyde, are relatively highly condensed and do not separate into layers when allowed to stand at room temperature for 48 hours or more. Accordingly, a plasticizer is not required although various well known fillers or extenders may be mixed into these resins for casting. Also, the castings prepared by my invention do not have to be case hardened oy ieating before being machined.

In preparing the resin solution for casting, it is acidied by addition of a suitable acid catalyst, agitated for 15-30 minutes or long enough to ensure a homogeneous solution, allowed to stand until air bubbles have escaped, and then poured into molds. The curing in the molds may take place at atmospheric pressure and at a suitable low temperature, such as 140 F. or lower.

The rate of cure of the resins after pouring depends upon various factors including the proportion of dihydric phenol in the product and the pH to which it is'adjusted. For example, a resin formulated with 50 parts of resorcinol to 100 parts of phenol and catalyzed by addition of suiiicient 50% hypophosphorous acid solution to lowei' its pH to 2.0 will gel in 11/2 hours and become glass hard in 31/2 hours at 140 F.

Strong mineral acids cannot be used as catalysts as the addition of a strong or highly ionized acid precipitates the resin from solution. Hypophosphorous acid is suitable if used in a fairly concentrated form such as a l0-50% solution. A 10-20% solution of this acid, however, is not satisfactory but causes precipitation. Various water soluble acids having an ionization constant not greater than 2.1 x 10-4 can be used and monochlorornonocarboxylic acids with an ionization constant not greater than 1.55 X 10-3 are also satisfactory. Formic, acetic, lactic, monochloroacetic, and monochloropropionic acids are examples of suitable catalytic or hardening agents for this purpose.

The terms and expressions which I have employed are used as terms of description and not of limitation, and I have no intention, in the of such terms and expressions, of excluding any equivalents of the features described or portions thereof, but recognize that various modifications are possible within the scope of the invention claimed.

What is claimed is:

l. A water soluble resin composition produced by reuxing a mixture of one mol of phenol with 1.3 to 2.5 mois of formaldehyde in an aqueous solution containing to 60% formaldehyde by weight at a pH of '7.5 to 8.8 in the presence of a non-volatile alkali catalyst until the reaction product contains less than 2% of free formaldehyde and tolerates the addition ci' from 0.1 to 5 volumes cf water without causing the resulting solution to become cloudy at 70 F. and refluxing the resulting product at a temperature not exceeding 100 C. with 10 to 150 parts of an unsubstituted mononuclear dihydric phenol for each 100 parts of said phenol until the condensation product has a Viscosity of from 0.5 poise to 1.65 poises at a solids content between 40 and 2. A water soluble resin composition produced by refluxing a mixture of one mol of mononuclear phenols selected from the class consisting of phenol, eresols and Xylenols with 1.3 to 2.5 mols of formaldehyde in an aqueous solution containing 30 to 60% formaldehyde by weight at a pH of 7.5 to 8.8 in the presence cf a nonvolatile alkali catalyst until the reaction product contains less than 2% of free formaldehyde and vtolerates the addition of from 0.1 to 5 volumes of solution containing 30 to 60%,fornialdelfiydevbi7V weight at a pH of 7.5 to 8.8 in the presence of a non-volatile-alkali catalyst,v untilthe reaction product contains less than 2%of free formaldehyde vandtolerates the additionpf fromv0..llto5 volumes .of water without causing theresulting solution to becomecloudy at 70F. andgreiiuxing the resulting product at a temperature not exceeding 100 C. with 10 to 150 parts of an unsubstituted mononuclear dihydric phenol for each 100 parts of said phenol until the condensation product has a Viscosity of from 0.5 poise to 1.65 poises at a solids content between 40 and 60% and vacuum distilling the resulting product until the viscosity is 20 to 200 at 70 F. as determined by a Stormer viscometer using a 500 gram Weight.

4. A water soluble resin composition produced by reuxing a mixture of one mol of phenol with 1.5 to 2 mols of formaldehyde in an aqueous solution containing 30 to 60% formaldheyde by weight at a pH of 7.5 to 8.8 in the presence of a non-volatile alkali catalyst until the reaction product contains less than .75% of free formaldehyde and tolerates the addition of from 0.1 to 5 volumes of water without causing the resulting solution to become cloudy at 70 F., adjusting the resulting product to a pH Within the range of 7.0 to 9.0, and reiiuxing the resulting product at a temperature between 80 to 90 C'. with 75 to 100 parts of an unsubstituted mononuclear dihydric phenol for each 100 parts of said phenol until the condensation product has a viscosity of from 0.5 poise to 1.65 poises at a solids content between-40 and 60%.

5. A Water soluble resin composition produced by reuxing a mixture of one mol of phenol with 1.3 to 2.5 mols of formaldehyde in an aqueous solution containing 30 to 60% formaldehyde by weight at a pH of 7.5 to 8.8 in the presence of a non-volatile alkali catalyst until the reaction product contains less than 2% of free formaldehyde and tolerates the addition of from 0.1 to 5 volumes of water Without causing the resulting solution to become cloudy at 70 F. and reiluxing the resulting product with to 150 parts of resorcinol at a temperature not exceeding 100 C'.

for each 100 parts of said phenol until the condensation product has a viscosity of 0.5 poise to 1.65 poises at a solids content between 40 and 60%.

6. A water soluble resin composition produced by reiluxing a mixture of one mol of phenol with 1.5 to 2.0 mols of formaldehyde in an aqueous solution containing 30 to 60% formaldehyde by weight at a pH of 7.5 to 8.8 in the presence of a non-Volatile alkali catalyst until the reaction product contains less than .75% of free formaldehyde and tolerates the addition of from 0.1 to 5 volumes of water without causing the resulting solution to become cloudy at 70 F., adjusting the resulting product to a pH within the range of 7.0 to 9.0 and reluxing the resulting product at a temperature not exceeding 100 C'. with 75 y to 100 parts of resorcinol for each 100 parts of said phenol until the condensation product has a viscosity of from 0.5 poise to 1.65 poises at a solids content between 40 and 60%.

7. A method of producing a water soluble resin composition which comprises reiiuxing a mixture of one mol of phenol With 1.3 to 2.5 mols of formaldehyde in an aqueous solution containing 30 to 60% formaldehyde by weight at a pH of 7.5 to 8.8 in the presence of a non-volatile alkali catalyst until the reaction product contains less thanf.2%4 of freeformaldehyde and tolerates the Iadditionfzof from.0.1 to 5.V olumes of wateruwthout= causing, the, resulting solution` to become cloudy. at 70B F. andzreiiuxing `ata..temp(211141111116, notexceeding 100'C.v the resulting product-with 10 to 150 parts. of. an .unsubsttuted mononuclear dihydri-c phenol vfor each .10.0. parts ,of 'said "phenol until' the. condensation. product ,has4 a, Viscosity of from 0.5 poise to 1.65 poises at a solids `content between 40 and 60%.

8. A process of producing 'a water soluble resin composition which comprises refluxing a mixture of one mol of phenol with 1.3 to 2.5 mols of formaldehyde in an aqueous solution containing to 60% formaldehyde by Weight at a pH of 7.5 to 8.8 in the presence of a non-Volatile alkali catalyst until the reaction product contains less than 2% of free formaldehyde and tolerates the addition of from 0.1 t-o 5 Volumes of water without causing the resulting solution to become cloudy at 70 F., refluxing at a temperature not exceeding 100 C. the resulting product with l0 to 150 parts of an unsu-bstituted mononuclear dihydric phenol for each 100 parts of said phenol until the condensation product has a viscosity of from 0.5 poise to 1.65r poises at a solids content between and and removing water from the product to obtain a viscosity of 20 to 200 at 70 F. as determined by a Stormer Vscometer using a 500 gram Weight. e

9. The method of producing :a water soluble resin compositi-on which comprises reiiuxing a mixture of one mol of phenol with 1.5 to 2.0 mols of formaldehyde in an aqueous solution containing 30 to 60% formaldehyde by weight at a pH of 7.5 to 8.8 in the presen-ce of a non-volatile a1- kali catalyst until the reaction product contains less than .75 of free formaldehyde .and tolerates the addition o-f from 0.1 to 5 volumes of water without causing the resulting solution to become cloudy at F., adjusting the resulting product to -a pH within the range of 7.0 to 9.0 and refluxing at a temperature not exceeding 100 C. the resulting product with to 100 parts of an unsubstituted mononuclear dihydrio phenol for each parts of sai-d phenol until the condensation product has a viscosity of from 0.5 .poise to 1.65 poises at a solids content between 40 and 60%.

l0. A method of producing a water soluble resin composition which comprises reiiuxing a mixture of one mol of phenol with 1.3 t-o 2.5 mols of formaldehyde in an aqueous solution containing 30 to 60% formaldehyde by weight at a pH between 7.5 and 8.8 in the presence of a non-Volatile alkali catalyst until the reaction product contains less than 2% of free formaldehyde yand tolerates the addition of from 0.1 to 5 volumes o-f water without causing the resulting solution to become cloudy at 70 F. and reiiuxing at a temperature not exceeding 100 C. the resulting product with 10 to 150 parts of resorcinol for each 100 parts of phenol until the condensation produ-ct has a viscosity of from 0.5 poise tc 1.65 poises at a solids lcontent between 40 and 60% ll. The method of producing a water .soluble resin composition which comprises reiluxing a mixture of one mol of phenol with 1.5 to 2 mols of formaldehyde in an aqueous solution containing 30 to 60% formaldehyde by weight at a pH between 7.5 and 8.3 in the presence of a nonvolatile alkali catalyst until the reaction product contains less than .75% vof free formaldehyde and tolerates the addition of from 0.1 to 5 volumes of y i1 12 water without causing the resulting solution to REFERENCES CITED become cloudy at 70 F" adjusting the resulting The following references are of record in the product to a. pH within the rang of '7.0 to 9.0 and m of this t nt. reuxing at a. temperature not exceeding 100 C. e pa e the resulting product with 75 to 150 parts of 5 UNITED STATES PATENTS resorcmol for each 100 parts of sand pilenol until Number Name Date the condensation product has a viscosity of from l 851 021 Schuette Mar 29 1932 0.5 poise to 1.65 poses at a solids content between 2150698 Nevin Mar' 14' 1939 40 and 60%. 2,489,336 Spahr et. al Nov. 29, 1949 RAYMOND J. SPAHR. 10 

1. A WATER SOLUBLE RESIN COMPOSITION PRODUCED BY REFLUXING A MIXTURE OF ONE MOL OF PHENOL WITH 1.3 TO 2.5 MOLS OF FORMALDEHYDE IN AN AQUEOUS SOLUTION CONTAINING 30 TO 60% FORMALDEHYDE BY WEIGHT AT A PH OF 7.5 TO 8.8 IN THE PRESENCE OF A NON-VOLATILE ALKALI CATALYST UNTIL THE REACTION PRODUCT CONTAINS LESS THAN 2% OF FREE FORMALDEHYDE AND TOLERATES THE ADDITION OF FROM 0.1 TO 5 VOLUMES OF WATER WITHOUT CAUSING THE RESULTING SOLUTION TO BECOME CLOUDY AT 70* F. AND REFLUXING THE RESULTING PRODUCT AT A TEMPERATURE NOT EXCEEDING 200* C. WITH 10 TO 150 PARTS OF AN UNSUBSTITUTED MONONUCLEAR DIHYDRIC PHENOL FOR EACH 100 PARTS OF SAID PHENOL UNTIL THE CONDENSATION PRODUCT HAS A VISCOSITY OF FROM 0.5 POISE TO 1.65 POISES AT A SOLIDS CONTENT BETWEEN 40 AND 60%. 